joe holvey sxi
Member
Registered: 12th Mar 10
Location: Bromborough, Cheshire
User status: Offline
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that manifold is car porn!
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jamied
Member
Registered: 27th Oct 03
Location: Marbella,Spain Drives: C63
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cant believe never noticed this before. Just spent hours reading this. one word... AMAZING!
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chris_uk
Premium Member
Registered: 8th Jul 03
User status: Offline
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need more!!!
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Rallycorsa
Member
Registered: 7th Dec 06
Location: Northumberland
User status: Offline
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This project is superb keep the updates coming, the manifold is a work of art.
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Efckitson
Member
Registered: 8th Jun 08
Location: Tamworth, Staffordshire
User status: Offline
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Porn tbh. Keep the updates coming 
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish hasn't worked on it a great deal lately but has been buying a few bits.
A mate put him onto a group buy on a dash, which after looking at it for a while he just couldn't turn down with 23% off.
He had always wanted a stack dash but they are now the best part of a grand so this seemed like the better option. Its made by a company called Race Technology, its obviously all digital so all the scales can be changed and which screens are displayed. The dash can be plugged directly into most aftermarket ECU's so it pulls all its information from there. That means there is no extra wiring loom or sensors.
The final exhaust bits landed from Nortech
He is going to be fitting 2 silencers to try and keep the noise under track limits, and plumbing the wastegate back into the downpipe. Also got flexibles for the main exhaust and wastegate pipe, and a couple of v-bands to split the exhaust down into 3 sections.
Lastly he bought a tial VD-R wastegate which replaced there old 44mm.
Propshaft is fitted up, which just fits due to the larger tube he made it out of. As you can see there isn't much room in the trans tunnel with that in there, which is why he went with the oval tubing to keep it above floor level. The exhaust is the final job to do under the car after than it can go back onto its wheels finally!
April '06' Corsasport Feature Car  | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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mwg
Member
Registered: 19th Feb 04
Location: South Lakes
User status: Offline
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awesome as always
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Robin
Premium Member
Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
User status: Offline
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Dash 2 is an awesome bit of kit, really nice to use
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Teddy
Member
Registered: 19th Jul 04
Location: Northampton Drives: VW Bora 1.9TDi pd130
User status: Offline
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Stunning build.
Great quality components as well.
Fair play!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish has been spending ages on the exhaust recently. Its turned into the most difficult thing he's ever made due to the oval tubing. He got a tool made up by Nortech to push into the oval tubing to make it round again for the transitions between the 2. This failed as the oval has more metal in it to get the same surface area as the round. This is due to a circle being the most efficent use of space.
The tool:
So the only option left, that was to make the transitions himself. He ended up splitting the oval and crushing one end in the vice then opening the end out to meet up with the circle. Then piecing in 2 fillets to complete them. The downpipe also has an oval bend which goes under the driveshaft which he made by splitting a 2.5" bend and widening it.
So here is the result of many hours of cutting, tweeking, and tacking it together.
Not much clearance to anything realy but that was always going to be the case with the 3.5" tubing.
He's very pleased with how the downpipe has turned out after all the work. The rest of it will be far easier as there isn't anything to avoid now!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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corsagsigav
Member
Registered: 28th Jan 08
Location: Retford, Nottinghamshire
User status: Offline
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that looks tight as a nuns
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Robin
Premium Member
Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
User status: Offline
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'kinell that's toight.
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8vcorsa
Member
Registered: 6th Dec 09
Location: Conwy
User status: Offline
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1 for the boys
that is a sexy car carnt wait to see more progress onit
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chunky_nb
Member
Registered: 19th Jan 07
Location: Bridgend S.Wales
User status: Offline
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SAVAGE! nice update dan, cheers
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allyp
Member
Registered: 14th Aug 07
Location: Torquay, Devon
User status: Offline
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such a good build I've been watching this one very closely, its very impressive i cant wait to see the finished article!!!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish has had another day on it today and got the centre section of the exhaust almost finished.
Another transition:
He split a 2.5" bend and opened it out to make an oval bend:
Some crap pictures of it on the car. It sits higher than the floor which is exactly what he was after with the oval tubing:
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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FAZ
Premium Member
Registered: 24th Nov 07
Location: Coventry
User status: Offline
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wow
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Russ
Member
Registered: 14th Mar 04
Location: Armchair
User status: Offline
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I'd give my left nipple for that when it's done.
the car, not my nipple
[Edited on 15-11-2010 by Russ]
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AlexW
Member
Registered: 25th Oct 08
Location: Essex
User status: Offline
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Is the CV boot not going to get melted by the downpipe?
Epic build, been reading it all.
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Jamie_Hastings1
Member
Registered: 14th Aug 08
Location: Sanquhar, Dumfries and Galloway
User status: Offline
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Not if its turning all the time,maybe on a long tickover it would distort it but a dont think it would melt it.
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish finally finished off the exhaust this weekend:
Back silencer and tailpipe:
Wastegate pipe plumbed back into downpipe and on v-bands either ends as the downpipe wont fit into place when its perminantly connected. He managed to get it to the bottom of the downpipe so hopefully it wont hurt the flow too much.
A tad tight down there now 
So it just needs the tacks ground flat and then off to be tig welded by the guy that did the manifold.
He has ordered a huge Garrett intercooler core from America:
Its 24"x 12"x 3.5" and good for 900bhp. More than will be needed for now but who knows what the future will hold.
He also has a couple of end tanks coming for it and a load of 3" boost piping which will be sorted the same way as the exhaust and then taken to Nortech for welding.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Robin
Premium Member
Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
User status: Offline
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Odd question but can you ask Hamish if he knows how long the engine is from the end of crank pulley to gearbox mounting face?
Or how long the cam cover is, I can work with that.
Cheers
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Tom
Member
Registered: 3rd Apr 02
Location: Wirral, Merseyside
User status: Offline
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How far are we away from video's of it making beautiful noises?
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish thought it was about time for an update. He hasn't got much done recently as it was too cold over christmas to get motivated, but he did get a little done.
The Race technology dash 2 is fitted on an alloy bracket mounted on rubber to try and damp out the vibrations.
The brake lines landed this week from HEL performance, stainless lines with stainless ends swaged by them and only £10 per line which he thought was a cracking price. Test fitted them today obviously they all need held with P clips to tidy them up but you get the idea.
The master cylinder for the front brakes is the smaller of the 2 and its using a double banjo bolt, which means there are seperate lines run to each front caliper. Then out of the larger master cylinder with a single banjo which has a brake light switch incorported into the top of it, this has a line running into the cabin for the rear brakes.
From the bulkhead into a bias valve which will be mounted next to the shifter.
From the bias valve into the handbrake cylinder and then a double banjo on the outlet to split the lines to go to the rear calipers.
A pack of P clips will have the lines looking a lot tidier, think it was worth getting them done this way rather than normal copper lines.
Hamish decided to refit the front arches, bumper and grill over christmas as he was sick of seeing them on the loft. Think this will be the first time its had all its bodywork on at the same time.
He did a little work to get the panel gaps half decent, its not being built to win show and shines so decided it was good enough for a track car.
He has taken the decision to take the alternator and power steering off the engine to further cut down the front end weight. So the alternator is going to be moved under the car and be driven off the propshaft and he's going to use an electric power steering column from a corsa. That now leaves nothing that can be moved, so hopeful its close enough to 50:50 weight distribution to stop any massive understeer.
This leaves lots of space at the front for the huge intercooler which is due this month.
Exhaust waiting to go and get welded when the boost pipes are done.
He has been slowly buying up parts for various jobs. Theres some exhaust wrap to stop the cv boot getting toasted and heat reflective tape to do the underside of the car where the exhaust gets close to the paint work. Waiting for it to warm up before he sticks that on. Also bought a Tial dump valve so it can have its flange welded on when the boost pipes are done.
Then there are some bits to get the plumbing sorted. A fuel lab fuel pressure regulator, holley lift pump, and a thermostat for the oil cooler.
So that brings it up to date at the moment. Like he said above the intercooler and boost pipes will be here this month so he can get them tacked up like the exhaust and off for welding. He has just put in a huge order of aeroquip fittings so all the fuel and oil lines can be run. There are 60 fittings in total which was rather painful paying for as they are expensive little things! They should be here next week. Then its down to an ecu and wiring before its finally running!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Jon_C
Premium Member
Registered: 7th Dec 05
Location: Suffolk
User status: Offline
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Awesome build. Any idea of the budget he had for this at the start of the build?
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